Apparatus and process for catalytic reactions



Dec. 13, 1949 E. J, GQHR ET AL 2,490,798

APPARATUS AND PROCESS FOR CATALYTIC REACTIONS Filed DeC. 30, 1942 3 Sheets-Sheet l A az-:M fr FIG -l l2! saam @wel Se WAT 5&2?

,QA/5g REMOVAL MG,

Dec. 13, 1949 E. GOHR ET AL 2,490,798

APPARATUS AND PROCESS FOR CATALYTIC REACTIONS Filed Dec. 50, 1942 3 Sheets-Sheet 2 125 2r/g 300 /LTE2` 23399:; Q 4 -n- 2.93 2&8 266 2 f CoA/veraz 28# rv L .f\f\/\ g STQRA 292 HQPPERS 5 DRY AIR UNE Dec. 13, 1949 E. J. Gol-R ET AL 2,490,798

APPARATUS AND PROCESS FOR CATALYTIC REACTIONS 3 Sheets-Sheet 3 Filed Dec. 30, 1942 Patented Dee. 13, 1949 UNITED STATES PATENT OFFICE APPARATUS AND PROCESS FOR CATALYTIC REACTIONS Edwin J. Gohr,

ford, Charles Tyson,

Summit, Homer Z. Martin, Cran- E. Jahnig, Roselle, Summit, and John M. Graham, Plainfield, N. J., assignors to Standard ment Company, a corporation of Charles W.

Oil Develop- Delaware Application December-30, 1942, serial 1510.470534 zone and assumes some of the characteristics of a liquid. The iluidized catalyst particles have a level located below the top of the reaction zone. Vaporous reaction products pass overhead and spent dry catalyst is removed from the bottom of the reaction zone in a dense i'luldized condition. Before being removed from the vessel forming the reaction zone, the spent catalyst is purged to remove volatile constituents irom the catalyst particles.

'I'he powdered catalyst is introduced into the bottom portion of the reaction zone and in the preferred i'orm of the invention the solid contact or catalyst particles are atarelatively high temperature and are mixed with preheated liquid or liquid and vapor reactants to supply the heat necessary to substantially completely vaporize the reactants and to supply the heat of reaction. Means `are provided i'or thoroughly mixing the liquid reactants 'and the powdered catalyst. The discharge end of the pipe or tube for introducing the catalyst into the reaction zone is arranged above .the bottom of the vessel of which a part forms the reaction zone and preferably has a ared or cone shaped end. Adjacent the discharge end of the inlet pipe the wall of the reaction zone may be constricted so that the velocity of the stripping gas passing from the stripping zone to the reaction zone does not fall below a minimum. An annular stripping zone is provided in the vessel below the dared or cone shaped outlet.

Where the level oi iiuidized catalyst inthe reaction zone is located some distance from the vapor outlet end of the reaction zone and the velocity of the vaporous reaction products leav ing the reaction zone is relatively low, only a small amount oi' catalyst particles is carried overhead with the reaction products. A cyclone separating means or other separating means is provided in the top of the reaction zone to remove most of the entrained catalyst particles passing overhead with the vaporous reaction products. 'I'he separating means is provided with a plurality of dip or return pipes oi diil'erent lengths to return the catalyst particles to the reaction zone when operating with diilerent levels of catalyst in the reaction zone. The separated reaction products in vapor form are then passed to suitable equipment for the separation of desired fractions.

In certain reactions the catalyst particles become inactivated or spent and it is necessary to regenerate them before using them again in another catalytic operation. As above pointed out, the catalyst particles in the reaction zone are maintained in a relatively dense iiuidized condi- A tion and ilow into the strippingzone from which or more dip or return they-are withdrawn and passed to a regeneration zone. .The withdrawn catalyst particles are mixed with a regenerating gas such as oxygen or air or other oxygen-containing gas and the mixture passed through the regeneration zone. During regeneration the velocity of the gases is so selected to give a iluidized bed of catalyst. The hot regenerated catalyst is withdrawn from the bottom of the regeneration zone and is introduced into a standpipe by means ci which it is returned to the reaction zone. The level of the catalyst particles undergoing regeneration is maintained at a certain distance from the top of the regeneration zone so that only a small amount of catalyst particles is entrained with the regeneration gases passing overhead.

The regeneration gases'- are passed through a separating means for separating solid particles from gases.

The separating means is arranged in the upper part of the regeneration zone. One

pipes are provided for returning the separated catalyst particles to the catalyst bed undergoing regeneration.

The regeneration gases leaving .the separating means still contain a small amount of powdered catalyst .or contact particles and the regeneration gases are introduced into an electrical precipitator or other separator to remove substantially all .ci the entrained catalystparticles from the regeneration gas. The catalyst particles recovered in the electrical precipitator are diillcult to iluidize and preferably coarser regenerated catalyst from the regeneration zone is introduced into the hopper below the precipitator to make a coarser mixture which can be iluidized. The last mentioned mixture is introduced into the top of a standpipe and then returned to the regeneration zone with a conveying gas.

In some cases insuillcient heat is obtained on` regeneration to heat the contact particles to the desired temperature and in such case heat is supplied to the regeneration zone by an auxiliary burner or oil may be injected into the regeneration zone.

In the drawings:

Fig. 1 represents one form of the invention which embodies the principles of the invention;

Fig. 1A representsa continuation of Fig. 1 and includes storage hoppers and associated parts for receiving catalyst or contact particles from the reaction vessels shown in Fig. 1 when the unit is to be shut down;

Fig. 2 represents a detail partly in section showing the mixing chamber for mixing the contacting agent and reactants;

Fig. 3 represents a vertical cross section taken substantially on line 3-3 of Fig. 2 and Fig. 4 represents a sectional view taken substantially on line 4--4 of Fig. 3 and showing nozzles for introducing the liquid feed into the powdered catalyst or contact particles.

Referring now to the drawings and to Fig. 1, the reference character I3 designates a line or pipe into which reactants are introduced through lines Il and Il' and catalytic material through line i2 as will be later described. The mixing of the liquid reactants and powdered material will be hereinafter described in greater detail. In certain reactions the reactants may beintroduced at ordinary temperatures and the heat necessary for preheating the reactants and for the reaction is supplied by hot regenerated catalyst or contact particles. In the catalytic cracking of hydrocarbons or other conversion operation the oil feed may be partly preheated by passing through heat exchangers but insuilicient heat is supplied to completely vaporize the oil feed or to supply the heat of reaction. Heat for vaporizing the oil and converting it is supplied by hot regenerated contact particles and no vaporizing furnace for the oil or reactants is necessary. The reactants introduced into line i are mixed in a mixing zone i3 (Figs. 1, 2 and 3) with hot regenerated catalyst or contact particles introduced into line i3 by means of line i2. As a result the liquid reactants are vaporized and raised to reaction temperature and the resulting mixture is passed through line I4 to the discharge end I3 of the pipe i4 which is flared or cone shaped to give a larger area for distributing the mixture in the reaction zone. The discharge end of the line i4 is provided with a distribution plate I3 which is provided with perforations for distributing the solid particles and the vaporized or gaseous reactants as they are discharged into the reaction zone 22 formed in larger vessel 23.

Where the pipes l0 and I2 are of a relatively large diameter the reactants are mixed with the hot catalyst particles by means of a plurality of pipes or smaller lines to more evenly distribute the reactants into the catalyst or contact particles as will be hereinafter described in greater detail.

The catalyst. or contact particles and vaporized or gaseous reactants after being introduced into the reaction zone 22 are maintained therein in a dry fiuidized condition having a level indicated at 24. The solid particles are maintained in a iluidized condition by selecting or maintaining the velocity of the gases or vapors at a desired ligure. The level shown at 24 is included only for the purpose of illustration and this level may be varied either to control the extent of the reaction or to carry out different reactions.

The reactants remain in contact with the solid or catalyst particles for the desired time to efiect the desired reaction. The catalyst or contact particles are maintained in a turbulent condition in the reaction zone and the reactants are contacted with the solid particles. A substantially uniform temperature is maintained throughout the fluidized bed of catalyst because ot the fluidized condition of the solid particles.

The reaction products in vapor form leave the uidized catalyst bed and pass upwardly through a separating means 23 which is shown in the drawing as a cyclone or multi-clone separating means. Preferably the separating means is arranged in the upper portion of the reaction zone or vessel 22. Other separating means may be used. The separating means 26 provides a means for separating dry entrained solid particles from the dry vaporous reaction products. The vaporous reaction products pass through line 28 to a fractionating system (not shown) or a system for separating desired products. The separated solid particles are collected in the hopper 32 associated with the separating means and returned to the catalyst bed in the reaction zone through one of a plurality of return dip pipes.

As shown in the drawing, a longer return pipe 34 and a shorter return pipe 35 are provided. The longer return pipe 34 is provided with a valve 38 and the shorter return pipe 35 has a valve 42. As shown in the drawing, the longer return pipe 34 extends into the bed of catalyst below the level 24 and this return pipe is used where the catalyst bed is relatively shallow. Where the catalyst level 24 rises above the shorter return pipe 35, the shorter return pipe 35 is used to return the catalyst to the catalyst bed. The valve 36 is manually operated from outside the reactor to maintain the pipe 34 substantially full of contact particles at all times when the longer pipe 34 is being used during the operation of the process.

When longer pipe 34 is used, valve 42 in shorter pipe.35 is closed. When the shorter pipe 35 is used. valve 42 is manually operated from outside the reactor to maintain the pipe 35 full of contact particles during the operation of the process and valve 36 in longer pipe 34 is closed. The extent of conversion may be controlled or changed by varying the height of catalyst level 24 in the reaction zone 22. Similar return pipes of different length may be used for returning catalyst from the cyclone separating means to the regeneration zone later to be described.

The vaporous reaction products leaving the separating means 26 contain a small amount of entrained catalyst and are passed through line 23 and introduced into suitable equipment for I separating desired products or fractions from the reaction products. Heavier constituents are condensed and entrained catalyst particles are collected in the condensate oil as a slurry. A portion or all of this slurry may be returned to the 60 reaction zone 22 as recycle through line Il.

Below the reaction vessel 22 and the discharge end I3 of the inlet pipe I0 an enlarged chamber 46 is provided in the bottom portion of the vessel 23 for receiving the catalyst particles from reac- 65 tion zone 22. As the spent catalyst leaves the bottom of reaction zone 22, it falls into an annular stripping zone 41 formed by cylinders 43 and 49.

Cylinder 43 is spaced from and supported by the inner wall of vessel 23. Inner cylinder 49 is supported from the edge of ilared discharge end I3 and hangs down into chamber 46. The stripping zone 41 terminates above the bottom of vessel 23. However, the stripping zone may be constructed and supported in other ways. Stripping zone 41 is provided to maintain the velocity of the stripping gases passing through zone 41 above a minimum velocity to obtain improved stripping. The flared discharge end I6 and the stripping zone 41 are arranged'to provide a compact arrangement and to provide a stripping zone oi' the desired size.

Circular headers 50 are provided which surround a portion of the cone shaped bottom of the reaction vessel or zone. A line 5 Iv associated with manifold 52 is provided for feeding a purging or iluidizing gas such as steam, normally gaseous hydrocarbons. or other inert gas to the circular headers. When using activated bentonite clays as convertion catalysts steam may be used as a purging gas, but when using a synthetic silicaalumina gel, the use oi other gases may be preferred.

From the circular headers 50, one or more inlet lines 53 extend into chamber 46 below stripping zone 41 for introducing stripping gas into this zone. Preferably line 53 feeds stripping gas into a ring 53a arranged below stripping zone 41. Ring 53a has a plurality of equally spaced openings in its upper part for distributing stripping gas over the cross section of the stripping zone 41. More than one ring may be used if desired.

The stripping or purging gas passing upwardly through the relatively dense uidized spent catalyst or contact particles substantially removes Volatile constituents therefrom. Another inlet line or lines 53' lead to the bottom of chamber 46 for fluidizing the purged catalyst introduced thereinto from the stripping zone. To prevent active catalyst from by-passing the reaction zone from the flared discharge end I6 to the stripping zone 41, a sleeve of about the same diameter as plate I8 may be placed on the ared discharge end'I6 to extend above the ared discharge end I6 for a short distance.

Preferably the reaction zone adjacent the discharge end I6 of the inlet pipe I4 has an annular inwardly projecting portion 54 for reducing the area of the reaction zone immediately above the discharge end I6. In this way the velocity of the reactants above the discharge end I6 of the inlet pipe I4 is maintained suiiiciently high to prevent settling of the catalyst particles. The stripping gas then passes upwardly through the bed of catalyst and out with the vaporous reaction lproducts. Portion 54 is shown on the drawing as an extension of cylinder 48 of the stripping zone but separate sections may be used.

If desired, the hopper 32 and the return pipes 34 and 35 may be provided with fluidizing inlets for introducing luidizing gas. In the draw- Aing a uidizing line 56 is shown for introducing gas into the lower portion of the return pipe 34. Lines 58 associated with circular headers 59 are shown for'introducing iiuidizing gas into the hopper 32. A uidizing inlet 62 is shown for the shorter return pipe 35. More than one fluidizing inlet may be used.

The purged spent catalyst is withdrawn from the bottom of the chamber 46 by means of standpipe 64. The standpipe 64 is provided with slide valves 66 and 68. The bottom valve 68 is used to control the amount of catalyst being withdrawn from the reaction zone 22. Slide valve 66 is provided as a spare. In case it is desired to shut down the system, both valves are closed. The standpipe 64 may also be provided with one or more iiuidizing inlets as shown at 69 to introduce i'luidizing gas, if desired.

The spent catalyst from the standpipe 64 is introduced into line 12 where it is mixed lwith a suitable regenerating gas introduced through line 14. 'Ihe regenerating gas may be any suitable oxygen-containing gas such as air or ue gas containing free oxygen. The regenerating gas may be at about atmospheric temperature or may be high temperature gas such as freshly produced combustion gases. The mixture of catalyst particles and regenerating gas forms a lighter or less dense mixture and the back pressure in the reaction zone 22 together with the head of uidized catalyst in the standpipe 64 and in the vessel 23 provides the necessary pressure for moving the spent catalyst through line 16 into the bottom portion of the regeneration zone 18. The regeneration zone 18 is provided with a perforated distribution plate 82 below which the mixture of spent catalyst and regenerating gas is introduced. The distribution plate functions to distribute evenly the catalyst and regenerating gas over the area oi the plate. The velocity of the gases passing through the regeneration zone 18 is s'o selected or maintained to fluidize the catalyst particles undergoing regeneration and so that the uidized catalyst particles maintaina level indicated at 84. The level is shown in one position in the drawing but may be varied if desired.

At one side the regeneration zone is provided with a vertically arranged baille 86 to provide a well 81 for receiving regenerated catalyst from the regeneration zone 18. With the level 84 arranged at a certain distance below the top ofthe regeneration zone there will be only a small amount of catalyst or contact particles entrained in the regeneration gases leaving the catalyst bed in the regeneration zone. In order to remove a large part of the entrained catalyst particles a separating means 88 is provided in the top portion of the regeneration zone 18. As shown in the drawing, the separating means is a cyclone separator or multi-clone separator but other forms of separating means may be used. The regeneration gases pass overhead through line 92. The separated solid particles are collected in a hopper 94 associated with the separating means 88.

If desired, the hopper 94 may be provided with headers 96, manifold 98 and inlet lines |02 for introducing fluidizing gas into the hopper to maintain the solid particles in uidized condition. The solid particles from the hopper 94 pass to a return pipe |06 provided with a manually operated damper or valve |08 near its lower end. The valve |08 is operated from the exterior of the unit to maintain the pipe |06 full of catalyst at all times during the operation of the unit. The return pipe I 06 may be provided with a iiuidizing line |09 for introducing iluidizing gas at one or more points to maintain the solid particles in fluidized condition. I

lFrom the well 81 the hot regenerated catalyst or contact particles in a dry dense iiuidized condition are withdrawn and passed to a standpipe II2 provided with slide valves II4 and II6. The bottom valve IIS is used to control the amount of catalyst or contact particles being introduced into line I2 for admixture with the reactants introduced into line I0. Top valve II4 is used asa spare. F'luidizing lines I I1 are provided for the standpipe II2 for introducing uidizing gas at one or more points in the standpipe to maintain the particles in fluidized condition. Air may be used as a iluidizing gas in lines II'I and inlet lines |02 for hopper 94, especially when cracking with synthetic catalyst. Steam is preferred for natural catalyst operation so as to reduce the quantity of non-condensible gases entering the reactor along with the regenerated catalyst. The standpipe H2 is a long apparatus and fiuidizing gas introduced into the lower half of the standpipe may be at a. higher pressure than iiuidizing gas introduced into the upper half of the standpipe.

Returning now to the regeneration gases leaving the regeneration zone 18 through line 92, the regeneration gases are passed through a waste heat boiler ||8 which is used for recovering heat from the regeneration gases while at the same time reducing the temperature of the regeneration gases. The waste heat boiler ||3 is provided with an inlet |22 and an outlet |24 for a cooling medium such as water for indirect heat exchange relationship with the regeneration gases to produce steam. The cooled regeneration gases are then passed through line |26 and introduced into the lower portion of a Cottrell precipitator |28 for removing the last traces of solid particles from the gases. Other separating means as a filter, screens or the like may be used. The' gases freed of powdered material are passed overhead through line |32 and may be vented to the atmosphere. A

The separated solid particles are collected in a hopper |34. If desired, headers |36 may be used having a manifold |38 and inlet lines |39 for introducing iluidizing gas into the hopper |34.

The solid particles recovered in the Cottrell precipitator are exceedingly fine and are difficult to uidize. In order to make a fluidizable mixture, coarser regenerated particles from the well 81 in the regenerator 18 are withdrawn through f line |44 and introduced into the hopper |34 associated with the Cottrell precipitator. A valve* |45 is provided in the line |44 for controlling the amount of coarser particles introduced into the hopper |34.

The mixture of fine and coarser solid particles is then introduced into a standpipe 52 provided with slide valves |54 and|56 similar in operation and construction to those above described. If desired, fluidizing inlets |51 may be provided for introducing fluidizing gas into the standpipe |52 at one or more points.

The fine solid particles together with the admixed coarser particles after leaving the standpipe |52 are mixed with a gas such as air introduced through line |58 and the mixture blown through line |62 and returned above the well 81 in regeneration zone 18 at the point |64.

When feed stocks are used which do not deposit suflicient burnable deposits to raise the temperature of the regenerated powdered catalyst or contact material to the desired extent, heat is added to the regenerated catalyst in other ways. For example, oil may be added to the regeneration zone 18 and burned therein ,to increase the temperature of the solid particles undergoing regeneration therein. A part or all of the oil slurry separated with the condensate oil recovered from A the reaction products as above pointed out may be injected into line 16 through line |90 or into regeneration zone 18 through line |92.

Instead of using the oil slurry or in addition thereto an auxiliary burner |94 may be used. Fuel, such as gas, is introduced into the burner |94 through line |96. As shown in the drawing a down ow burner is used but other forms of burners may be used. Air to support combustion is introduced into the top of the burner |94 through line |98. Preferably the fuel line |96 and air line |98 are so interconnected by controls that the fuel is automatically turned off if the air supply is turned off for any reason. The air is first compressed in compressor 202 to a pressure of about 10 to 15 ibs. per square inch and one part thereof passed to burner |94 through line |98, another part thereof passed through line 204 and line 206 to be used as quenching air introduced into the lower part of burner |94 to reduce the ytemperature of the combustion gases leaving the burner |94 through line 208 supplying line 14 to about 1250 F. The quench air also supplies the rest of the regenerating gas for regenerating the spent catalyst in the regeneration zone 18. A portion of the compressed air passing through line 204 is passed through line 2 |2 to remove part of the moisture from the air as wi1l be eration and the contact particles are heated to a.

temperature of about 1050 F. to 1200 F. so that the contact particles will have a suiciently high temperature to heat the reactants and also to supply the heat of reaction. In cases where the auxiliary burner |94 is not needed regenerating gas at ordinary temperature may be introduced through line 14 intoline 12.

The portion of the air passing through line 2 I2 is passed through a cooler 2|4 having an inlet 2 I6 and an outlet 2 I 8 to remove heat of compression and to reduce the temperature of the compressed air to about '70 F. to 110 F. At this temperature water is condensed and collected in drip drum 222 into which the cooled compressed air is introduced. Water is removed from drum 222 through valved outlet .224 and the partially dried air leaves the top of the drum through line 226.

In certain cases it is desirable to have relatively dry air for use as a uidizing means or as a means for transferring relatively cool powdered material as will'be hereinafter described. The compressed air isnot completely dried but has been cooled to a temperature lower than will be encounteredin the process and therefore no condensation of water will result when the dried air is mixed with relatively cool powder.

When it is desired for any reason to shut down the unit, the fuel to the auxiliary burner |94 is turned off vbut not the air, and feed of reactants to the unit is4 turned off. The valves at the bottom of standpipes |'|2 and |52 are closed. The reaction zone 22 is purged with steam introduced from line 5| through line 53 adjacent stripping zone 41, line 53'. enteringthe bottom portion of chamber 46 and line 221 which leads into the bottom portion of an upwardly directed tube 228 forming an extension of feed line l0. Then as much as possible of the catalyst from the reaction zone 22 is emptied into the regeneration zone 18 via standpipe 64 and lines 12 and 16. The vent line 28 from reaction zone 22 is shut off to the fractionating equipment in any suitable mannerand the dust laden gas is passed to the Cottrell precipitator through valved line 229.

The steam lines 5| and 221 are then closed and air is passed into line 228 through line 232 and through line228 leading to lines 53 and 53' from line 208. Valves 4 and ||6 in standpipe ||2 are then partly opened to permit recycling of catalyst at a low rate from the reaction zone 22 to the regeneration zone 18, etc. while the unit cools to about 300 F. to 500 F.

p with line 268 leading to bag filter.

Drawoi line 236 connects with standpipe II2 above valve ||4 and has a valve 238 and drawoi! line 242 connects with standpipe |52 above valve |54 and has a valve 244. Valves 238 and 244 are opened and iluidized catalyst or contact particles ilow into lines 236 and 242 respectively. Dry air from line 226 is passed through lines 246 and 248 into lines 236 and 242, respectively, for forming a relatively light suspension of the powdered material. The two lines 236 and 242 empty into line 252 (see Fig. 1A) and the powdered material is sent through a cooler 254 where it is in indirect heat exchange with a cooling medium introduced into cooler 254 at 256 and leaving the cooler at 258. If no cooling of the catalyst is necessary, cooler 254 is by-passed and the catalyst is passed through line 259. A part of the cooled catalyst may be removed from the system through line 260. Or catalyst may be removed from by-pass line 259 through line 26|.

The powdered material at a temperature of about 150 F. to 600 F. passes through line 262 into the upper portion of a storage hopper 264 where separation of solid particles from carrying gas is elected. The top portion of hopper 264 has an outlet line 268 for dust laden gas which passes to a bag filter or the like 212. The bag` and 294. only the bottom row of aerating lines storage hoppers. When all powdered material is removed from theunit the ilow of all gasI is stopped to the hoppers.

filter is connected with exhauster 266 by line 214.

Exhauster 266 has outlet 216 to the atmosphere. In the bag filter powdered solid material is separated from gas and drops into the bottom portion of iilter 212 from which it is removed by a star feeder 218 to a conveyor 282.

The conveyor 282 has a means diagrammatically shown at 284 for rotating it and is further provided with two screw portions 286 and 288. y

When the conveyor is rotated in one direction screw portion 286 operates to move separated powdered material from lter 212 to the top ot' storage hopper 264 through line 292 and'when the conveyor is rotated in the opposite direction the screw portion 288 operates to move separated powdered material from lter 212 to the other storage hopper 294.

When storage hopper 294 is to be used the suspension in line 262 by-passes storage hopper 264 and passes through line 296 to hopper 294. Hopper 294 also has a line 298 connecting it with the bag lter 212. Line 299 connects line 298 Lines 298 and 299 are open to the atmosphere at all times Y,

via line 300 so that it is impossible to have a subatmospheric pressure in the storage hoppers.

During removal of catalyst from the system the regenerator and Cottrell standpipes are the ones/ used as the removing means. Catalyst is moved from the reaction zone 22 to the regeneration zone 18 and is then removed from the regenerator well 81.

Storage hopper 264 is provided with aeration lines 302 for introducing fluidizing gas into the bottom portion of the hopper when it is desired to remove catalyst from the hopper and pass it to the unit. For forcing the fluidized mixture from either storage tank 264 or 294 fluid under superatmospheric pressure is supplied to the hopper selected. In starting up the unit, the catalyst is cold and if compressed atmospheric air were used, condensation of water would result in the catalyst and lumps would form or even plugging of the lines might occur. Therefore, it is desirable to use the partly dry air from line 226 as a iluidizing means in lines 302. Storage hopper 294 also has aerating lines 304. For aerating or uidizing the powdered material in hoppers 264 The feeding of reactants to the unit will now be described. When the reactants are liquid such as crude petroleum oil, gasoil or the like, it is necessary to obtain proper mixing of the hot regenerated catalyst and the liquid reactants. See Figs. 2, 3 and 4. Catalyst is introduced into line I0 from line I2 and oil is introduced through a' plurality of nozzles 3|2 arranged in a circle within line or pipe 0. The nozzles introduce the oil at Vhigh velocity to obtain intimate mixing with the catalyst. The nozzles are arranged downstream from the catalyst inlet and therefore to prevent build-up of catalyst at the bottom 3|4 of pipe I0 and in extension 228, a valved inlet 3|6 is provided for introducing a gas into` the bottom portion of extension 228. With ordinary clay catalysts, steam or other inertgasmay be used, but where synthetic gels are used, preferably normally gaseous hydrocarbons or gaseous hydrocarbons from the absorption plant or other inert gases may be used as a gas for introduction through line 3| 6. Line 228 has a safety valve connection 3|8. f

In Fig. 3 it will be seen that oil is`pumped through line l by pump 326 and then into branch lines forming continuations of line I l which connect with the nozzles 3 I 2. As shown in the drawing there are nine nozzles but the number may be varied as desired. The lines 328 leading to the nozzles are bent at 332 so that the nozzles 3l2 are spaced from and parallel to the wall of pipe I0 and point in a direction away from the bottom 3|4 of pipe I0, that is, they point downstream. 'l

Another set of nozzles 336 is provided having branch lines Il' for feeding oil slurry or cycle oil into the catalyst or contact particles passing through pipe I0. Instead of using two sets of nozzles, only one set may be used for feeding the oil and slurry to the pipe I0 but two sets of nozzles are preferred so as to have a minimum number of nozzles which are exposed to the erosive action of the slurry.

While the invention may be used for carrying out catalytic reactions generally, specific examples will now be given to illustrate `how the invention is used in the catalytic conversion of hydrocarbons. For the catalytic cracking of relatively heavy hydrocarbons such as reduced crude, gas oils or the like and in order to obtain about 45% conversion to gasoline a catalyst is used such as acid treated bentonite clays or synthetic gels containing silica and alumina or silica and magnesia. For preparing gasoline having a relatively high octane number a synthetic gel catalyst is used. The catalyst or contact material is preferably in powdered form of a size mainly between 200 and 400 standard mesh or ner and containing about 5% to 25% of particles having a size between 0 and 20 microns.

In the catalytic cracking of a reduced crude oil the cracking temperature in the reaction zone is about 980 F. and the regeneration temperature is about l F. With the reduced crude oil preheated to a temperature of F. and in order to supply the heat of vaporization and oi cracking a mixture of inert solid particles and 1l catalyst particles is used. The ratio of solid material to the crude oil by weight is about 25 to 1. The catalyst is included in this solid to oil ratio and the amount of catalyst in the mixture is-about in the proportion of 9 to 1 part of oil by weight. The velocity of the vapors and gases in the reaction zone and the regeneration zone is about 1.5 feet per second. With this velocity the fluidized mixture-in the reaction zone 22 has a density of about 10 to 20 pounds per cubic foot and the density of the suspension above the catalyst bed 2l is much smaller, de-

creasing to about 0.002 to 0.01 pound per cubic f oot at the cyclone inlet. The regeneration zone is maintained under a pressure of about 1 pound per square inch gauge and the reaction zone is maintained under a pressure of about 9 pounds per square inch gauge. The reason for maintaining the reaction zone under a slight pressure is to provide suiiicient pressure to overcome pressure drop through the outlet lines and fractionating or other equipment used to recover gasoline and other fractions.

In another example a relatively light gas oil is used for producing aviation gasoline. A light East Texas gas oil having a 37 A. P. I. gravity, a mid-boiling point of about 540 F. and a final boiling point of about 700 F. is preheated to about 400 F. after having passed through heat exchangers not shown in the drawing. The preheated gas oil is mixed with the hot regenerated catalyst which is at a suiliciently high temperature to heat and vaporize the gas oil and to maintain it at the conversion temperature desired. In this case no solid inert material is added to the catalyst and only catalyst particles are used. In some cases, however, inert solid particles may be added.

The catalyst is in iinely divided form and has particles of a size of 200 to 400 standard mesh or finer. The catalyst may be any suitable cracking catalyst but for the production of aviation gasoline a synthetic gel catalyst containing silica and alumina or silica and magnesia is preferred.

In order to supply the necessary heat of vaporization and of cracking and to obtain about 30% conversion of the gas oil to aviation gasoline about '7.5 parts of catalyst comprising the synthetic gel, silica-alumina, to one part of oil by weight are used. lThe temperature during crackingsis about 700 F. to about 850 F. 'Ihe uidized mass of catalyst particles in the reaction zone 22 has a density of about 12 to 16 pounds per cubic foot and the velocity of the vaporous products leaving the reaction zone 22 is about 1 to 2 feet per second. The velocity of the regenerating gas in regeneration zone 18 is about 1 to 1.5 feet per second and with this lvelocity the catalyst particles in the regeneration zone are maintained in the iluidized condition and have a density of about 12 to 16 pounds per cubic foot. Due to the turbulent condition of the catalyst particles in the regeneration zone the temperature during regeneration is maintained substantially uniform throughout the fluidized mass and is about 1050" F. The hot regenerated catalyst at about 1050 F. flows down the standpipe H2 and is directly mixed with the light gas oil to supply heat of vaporization and heat of reaction or conversion.

While certain velocities have been given for the vapors leaving the reaction zone 22 and the regeneration gas leaving the regeneration zone catalyst, stripping by a gas the spent catalyst 12 18, it is to be understood that other velocities may be used between about 0.5 and 1.5 feet per second. The regeneration temperatures may be varied but when acid treated bentonite clays are used the temperature during regeneration is preferably maintained below about 1200 F. Higher regeneration temperatures than 1200 F. may be used with synthetic gel catalysts. higher regeneration temperatures, less catalyst or solid particles will be necessary for vaporizing the gas oil or other feed and maintaining it at the reaction temperature.

With the nozzles 3l2 arranged as shown in Fig. 2, the nozzles are surrounded by a stream of solid particles in pipe I4 to prevent splashing of the liquid oil against the wall of pipe Il where coke deposits might form and so as to prevent the accumulation of liquid oil in any part of the reactor inlet line M.

In the examples given above the conditions may be varied without departing from the spirit of the invention.

While the invention has been particularly described in the examples in connection with catalytic cracking of hydrocarbon oils, it is to be understood that it may be used in other catalytic conversions of hydrocarbons such as reforming, hydroforming, alkylation, polymerization, dehydrogenation, etc. and may also be used in other catalytic reactions, such as, oxidation, reduction, chlorination, shale distillation, coal carbonization, etc. y

While one form of apparatus has been shown in the drawing and specific examples have been given, it is to be understood that these are by way of illustration only and various changes and modifications may be made without departing from the spirit of the invention.

An additional case covering :features not claimed herein was led on or about October 6, 1949, and bears Serial No. 119,912.

What is claimed is:

1. An apparatus of the character described including a vessel, means for introducing uid and powdered solid material into said vessel comprising a standpipe and a tubular member extending through the bottom of said vessel and terminating in the lower part of said vessel in an upwardly directed flared discharge portion, a second standpipe through which solid particles are withdrawn from the bottom of said vessel, an outlet for fluids and entrained solids yfrom the upper portion of said vessel, separating means in the upper portion of said vessel for separating fluids from entrained solids in a dry separation, and a plurality of return pipes of different lengths extending downward from said separating means for returning the separated powdered solid to said vessel at different levels thereof.

2. A process for carrying out catalytic reactions which comprises introducing a mixture of reactants and hot powdered catalyst into the lower portion of a reaction zone, dispersing the mixture so as to distribute the same evenly across the reaction zone, the reaction zone being reduced in cross-section above the locus of dispersion in said reaction zone to maintain the desired velocity of the reactants above said locus of dispersion in said reaction zone, supplying the heat of reaction by the powdered catalyst, maintaining a bed of fluidized catalyst particles in said reaction zone, withdrawing spent catalyst particles from said reaction zone into a stripping zone below the point of dispersion of the hot When using in said stripping zone and passing the stripping gas from said zone to said reaction zone.

3. An apparatus for contacting solids with gases which comprises an outer shell consisting of a vertical cylindrical section and end walls forming a closed vessel, a conduit extending through the lower portion of said shell having an enlarged open en'd' terminating in the lower intermediate portion of said shell and having its enlarged open end opening upwardly therein, a horizontal foraminous member extending over the inner open end of said conduit, said conduit being adapted to introduce a dispersion of finely divided solids and gas into said vessel, a sleeve secured to the outer periphery of said enlarged end and extending in spaced parallel relation with the inner wall of s aid cylindrical section to form anannular' stripping zone, means for introducing an extraneous gas at a plurality of points into the lower portion of said annular stripping zone, a second conduit communicating with the bottom of said chamber adapted to withdraw finely divided solids therefrom and a third conduit communicating with the upper end of said vessel and adapted to remove gases therefrom.

4. An apparatus according to claim 3, provided with a separating means positioned inside the upper end oi said vessel and adapted to separate entrained solids from the gases leaving said vessel.

5.` An apparatus according to claim 4, wherein the separating means are provided with return pipes of different lengths for discharging at various levels in said vessel the solids segregated from the gases in said separating means.

6. An apparatus of the character described including a vessel having a cone-shaped bottom, a tubular member extending into sa/id vessel through said cone-shaped bottom and having a iiared discharge end arranged in a horizontal position above the bottom of said vessel, a distribution grid member in said discharge end, means comprising a standpipe to pass a uid and a' powdered contact solid through said tubular vmember and distribution grid member into said vessel, the cross-section of said vessel directly above said ilared discharge end being smaller than the cross-section of the top of said vessel, means for maintaining the powdered solid in a fluidized condition in said vessel above said ilared discharge end, a stripping chamber in the bottom portion oi' said vessel below said iiared discharge end, means comprising a second standpipe fory withdrawing powdered solid from the bottom oi said vessel, said flared discharge end extending to near the inner wall of said vessel to provide an annular space having a cross section smaller in size than that of the vessel for the passage of a stripping gas and thereby maintaining above a minimum the velocity of the stripping gas passing through said stripping chamber to said vessel above said ared discharge end.

7. A process for carrying outy catalytic re-A ture in the lower portion oi' the reaction zone immediately adjacent the 'point of discharge at a velocity higher than the velocity of the mixture in the upper portion of the reaction zone, maintaining a bed of dry luidized catalyst' in said reaction zone, downwardly withdrawing spent catalyst as an annulus of constant cross section from the lower end of said reaction zone and below the point of discharge of catalyst and reactant into said reaction zone, uniformly stripping the annulus of catalyst with a plurality of streams of stripping gas, said streams being spaced throughout the horizontal cross-section of said annulus and passing the stripping gas from said stripping step into the bed of dry iiuidized catalyst in said reaction zone.

8. In an apparatus for converting hydrocarbons in combination, a reaction vessel, means for forming a -gaseous suspension of hot powdered freshly regenerated catalyst in an upwardly extending inlet pipe to the reaction vessel constituting a mixing zone external of said reaction vessel, means for introducing liquid hydrocarbon oil at high velocity upwardly into said suspension in the inlet pipe through a plurality of elongated nozzles arranged within the inlet pipe, said nozzles being spaced from and parallel to the confining surface of said inlet pipe to mix the catalyst and oil uniformly and to varporize the oil so that the resultant mixture is substantially dry and to prevent splashing of the liquid oil against the wall of said lmet pipe, and means for uniformly distributing the mixture of catalyst and oil vapor into the reaction vessel.

EDWIN J. GOHR. HOMER Z. MARTIN. CHARLES E. JAHNIG. CHARLES W. TYSON. JOHN M. GRAHAM.

BEFEBEN CES CITED The following references are of record in the le of this patent:`

UNITED STATES PATENTS Number Name Date 816,460 Geisendorfer et al. Mar. 27, 1906 1,984,380 Odell Dec. 18, 1934 2,253,486 Belchetz Aug. 19, 1941 2,270,903 Rudbach Jan. 27, 1942 2,303,047 Hemminger Nov. 24, 1942 2,304,128 Thomas Dec. 8, 1942 2,325,516 Holt et al. July 27, 1943 2,337,684 Scheineman Dec. 28, 1943 2,340,974 Myers Feb. 8, 1944 2,341,193 Scheineman Feb. 8, 1944 2,356,697 Rial Aug. 22, 1944 2,361,978 Swearingen Nov. '1, 1944 2,362,270 Hemminger Nov. 7, 1944 2,363,874 Krebs Nov. 28, 1944 2,367,694 Snuggs Jan. 23, 1945 2,384,356 Tyson Sept. 4, 1945 2,388,078 Reeves Oct. 10, 1945 2,402,893 Hulse June 25, 1946 2,439,811 Jewell Apr. 20, 1948 FOREIGN PATENTS Number Country Date 115,689 Australia --.l Aug. 6, 1942 

